Removal & Installation

If equipped with Active Electronic Control Suspension (Active-ECS) perform the following:

Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.

Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.

Disconnect the lower ball joint and the tie rod end from the steering knuckle.

If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.

If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.

Remove the cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.

Remove the lower ball joint cotter pin.

NOTE

Do not remove the nut from the ball joint. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE

When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

Tighten the bolt with a wrench to disconnect the lower arm ball joint connection.

Remove the tie rod end cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.

NOTE

Do not remove the nut from the tie rod end. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE

When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

Tighten the bolt with a wrench to disconnect the tie rod end.

Disconnect the stabilizer link connection.

NOTE

Do not damage the ABS rotor attached to the BJ outer race, on vehicle equipped with ABS.

Use special tools MB991354, MB990242 and MB990767 to push the halfshaft out from the hub.

NOTE

Do not pull on the halfshaft, doing so will damage the TJ. Be sure to use a prybar. Do not insert the prybar so deep as to damage the oil seal.

Insert a prybar between the transaxle case and the halfshaft to remove the halfshaft on vehicles equipped with 2.4L engine and vehicles equipped with 3.0L engine (left side shaft).

If the inner shaft and transaxle are tightly joined, tap the center bearing bracket with a plastic hammer to remove the halfshaft and inner shaft from the transaxle on vehicles with 3.0L engine (right side).

If equipped with Active Electronic Control Suspension (Active-ECS) perform the following:

Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.

Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.

Disconnect the lower ball joint and the tie rod end from the steering knuckle.

If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.

If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.

Remove the cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.

Remove the lower ball joint cotter pin.

NOTE

Do not remove the nut from the ball joint. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE

When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

Tighten the bolt with a wrench to disconnect the lower arm ball joint connection.

Remove the tie rod end cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.

NOTE

Do not remove the nut from the tie rod end. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE

When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

Tighten the bolt with a wrench to disconnect the tie rod end.

Disconnect the stabilizer link connection.

NOTE

Do not strike the ABS rotor attached to the BJ or EBJ outer race, of the halfshaft against other parts when removing the halfshaft as damage to the rotors will result.

Use special tools MB991354, MB990242 and MB990767 to push the halfshaft out from the hub.

NOTE

Do not pull on the halfshaft, doing so will damage the TJ or PTJ. Be sure to use a prybar. Do not insert the prybar so deep as to damage the oil seal.

Remove the halfshaft from the hub by pulling the bottom of the brake disc towards you.

Insert a prybar between the transaxle case and the halfshaft, and than pry and remove the halfshaft from the transaxle.

NOTE

Insert a prybar, taking care not to damage the protrusion of the transaxle case when removing the halfshaft (left side).

If the inner shaft and transaxle are tightly joined, tap the center bearing bracket with a plastic hammer to remove the halfshaft and inner shaft from the transaxle on vehicles with 3.0L engine (right side).

If equipped with Active Electronic Control Suspension (Active-ECS) perform the following:

Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.

Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.

Disconnect the lower ball joint and the tie rod end from the steering knuckle.

If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.

If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.

Install the washer so the chamfered edge faces outward. Install the nut and tighten to 181 ft. lbs. (245 Nm). Secure with a new cotter pin.

Connect the ball joint to the steering knuckle. Torque the new retaining nut to 43-52 ft. lbs. (60-72 Nm) and secure with a new cotter pin.

Connect the tie rod end to the steering knuckle. Torque the retaining nut to 21 ft. lbs. (29 Nm) and secure with a new cotter pin.

If equipped with ABS, install the front wheel speed sensor.

If equipped with Active-ECS, perform the following:

Install the air line with a new O-ring.

Install the actuator to the top of the strut. Connect the wiring harness.

Install the wheel and lower the vehicle to the floor.

Raise and support the vehicle safely.

If equipped with ABS, disconnect the speed sensor connection. Remove the ABS sensor and bracket. Remove the brake hose clip.

Remove the stabilizer bar locknut, rubber insulator and collar.

Remove the cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.

Remove the lower ball joint cotter pin.

NOTE

Do not remove the nut from the ball joint. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE

When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

Tighten the bolt with a wrench to disconnect the lower arm ball joint connection.

Remove the tie rod end cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.

NOTE

Do not remove the nut from the tie rod end. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE

When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

Tighten the bolt with a wrench to disconnect the tie rod end.

NOTE

Do not damage the ABS rotor attached to the BJ outer race, on vehicle equipped with ABS.

Use special tools MB990241 and MB990767 (vehicles without center bearing) or tools MB991354, MB990242 and MB990244 (vehicles equipped with center bearing) to push the halfshaft out from the hub and knuckle.

Remove the halfshaft from the hub by pulling the bottom of the brake disc toward you, and than remove the hub retaining bolts.

NOTE

Do not pull on the halfshaft, doing so will damage the TJ or ETJ. Be sure to use a prybar. Do not insert the prybar so deep as to damage the oil seal.

Insert a prybar between the transaxle case and the halfshaft, and then pry the halfshaft from the transaxle.

If the inner shaft and transaxle are tightly joined, tap the center bearing bracket with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.

If equipped with Active Electronic Control Suspension (Active-ECS) perform the following:

Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.

Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.

Disconnect the lower ball joint and the tie rod end from the steering knuckle.

If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.

If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.

Install the washer so the chamfered edge faces outward. Install the nut and tighten to 145-188 ft. lbs. (200-260 Nm). Secure with a new cotter pin.

Connect the ball joint to the steering knuckle. Torque the new retaining nut to 43-52 ft. lbs. (60-72 Nm) and secure with a new cotter pin.

Connect the tie rod end to the steering knuckle. Torque the retaining nut to 21 ft. lbs. (29 Nm) and secure with a new cotter pin.

If equipped with ABS, install the front wheel speed sensor.

If equipped with Active-ECS, perform the following:

Install the air line with a new O-ring.

Install the actuator to the top of the strut. Connect the wiring harness.

Install the wheel and lower the vehicle to the floor.

Front

Fig. Front halfshafts and related components

Before servicing the vehicle, refer to the Precautions Section.

Disconnect the negative battery cable.

Raise the vehicle and support safely. Remove the lower ball joint and the tie rod end from the steering knuckle.

Remove the cotter pin, halfshaft nut and the washer.

On vehicles with an inner shaft, remove the center support bearing bracket bolts and washers.

On vehicles with an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Then, tap the shaft union at the joint case with a plastic hammer to remove the halfshaft shaft and inner shaft from the transaxle.

Fig. Front halfshaft removal

On vehicles without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle. Do not pull on the shaft.

Do not remove the nut from the ball joint. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE

When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

Tighten the bolt with a wrench to disconnect the lower arm ball joint connection.

Remove the tie rod end cotter pin. Install tool MB990767 to the hub and remove the halfshaft nut. Remove the washer.

NOTE

Do not remove the nut from the tie rod end. Loosen it and use special tool MB991897 to avoid possible damage to the ball joint threads. Hang the special tool in place with wire or string to prevent it from falling.

Install the special tool. Turn the bolt and knob as necessary to make the jaws of the tool parallel. Tighten the bolt by hand and confirm that the jaws are still parallel.

NOTE

When adjusting the jaws in parallel, make sure the knob is in the vertical (upward) position.

Tighten the bolt with a wrench to disconnect the tie rod end.

NOTE

Do not strike the ABS rotor attached to the EBJ outer race, of the halfshaft against other parts when removing the halfshaft as damage to the rotors will result.

Use special tools MB990241 (MB990242 and MB990244), MB991354 and MB990767 to push the halfshaft out from the hub.

Remove the halfshaft from the hub by pulling the bottom of the brake disc toward you, and than remove the hub retaining bolts.

NOTE

Do not pull on the halfshaft, doing so will damage the TJ. Be sure to use a prybar. Do not insert the prybar so deep as to damage the oil seal.

Insert a prybar between the transaxle case and the halfshaft, and then pry and remove the driveshaft from the transaxle.

To install:

Installation is the reverse of the removal procedure.

Check and adjust the front end alignment, as necessary.

Fig. Halfshaft and related components-Evolution

Rear

Before servicing the vehicle, refer to the precautions at the beginning of this section.

Raise and safely support the vehicle.

Remove the rear wheel.

Remove the rear wheel speed sensor.

Remove the caliper and rotor.

Remove the brake hydraulic line from the wheel cylinder.

Remove the parking brake cable from the rear brakes.

Remove the lower end of the shock absorber from the knuckle.

Remove the trailing and lower arms from the knuckle.

Remove the toe control arm ball joint from the knuckle.

Prevent the hub assembly from turning by using a tool such as MB990767 and remove the halfshaft nut and washer.

Remove the differential mount support.

WARNING

Do not pull on the halfshaft to remove it from the differential. Damage to the inner CV-joint will occur.

Push the lower part of the knuckle outward and pry the inner halfshaft out of the differential.

Push the outer end of the halfshaft through the hub/knuckle and remove it.

To install:

Install the outer end of the halfshaft through the hub/knuckle.

Place a new circlip on the inner halfshaft and install the halfshaft in the differential.

Install the differential mount support.

Install the washer and a new nut on the end of the halfshaft. Tighten the nut to 145-188 ft. lbs. (196-255 Nm).

Install the toe control arm to the knuckle. Tighten the new nut to 20 ft. lbs. (28 Nm).

Install the lower and trailing arms to the knuckle. Do not tighten the fasteners at this time.

Install the shock absorber. Tighten the bolt to 71 ft. lbs. (98 Nm).

Assemble the brake components.

Install the rear wheel speed sensor.

Install the rear wheel and lower the vehicle to the floor. Tighten the lower arm nut to 71 ft. lbs. (98 Nm) and the trailing arm nut to 85-99 ft. lbs. (118-137 Nm).

Manual Transaxle

Fig. Remove the cotter pin from the axle shaft . . .

Fig. . . . then loosen the axle nut while the vehicle is still on the ground

Fig. Remove the lower coil-over shock lower mounting bolt and nut from the control arm

Fig. Use a suitable prytool to separate . . .

Fig. . . . the lower ball joints from the steering knuckle

Fig. Use a suitable prytool to release the inner CV-joint retaining ring from the transaxle by gently prying outward

Fig. Remove the inner joint from the transaxle until the spline completely clears the transaxle

Fig. Using a suitable punch and hammer, gently tap the halfshaft out of the steering knuckle . . .

Fig. . . . then slide the halfshaft out of the knuckle

Fig. Remove the halfshaft from the vehicle

Fig. Always replace the circlip on the inner joint before installing the shaft into the transaxle

While the vehicle is still on the ground, remove the cotter pin, and loosen the axle nut.

Raise the vehicle and support it safely.

If equipped with ABS, remove the front wheel speed sensor.

If equipped with Active Electronic Control Suspension (Active-ECS), perform the following:

Loosen the nut that secures the air line to the to the top of the strut and discard the O-ring.

Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.

Disconnect the lower ball joint and the tie rod end from the steering knuckle.

Remove the axle nut and the washer.

If removing the left side axle with an inner shaft, remove the center support bearing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic hammer to remove the halfshaft and inner shaft from the transaxle.

If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.